Art of forming composite plastic devices



Dec. 29, 1964 R. o. nusEL ETAL. 3,163,686

ART oF FORMING coMPosITE PLASTIC DEVICES Filed April 2, 1952 if?. Z

n SOURCE 3 34 34 INVENToR. Rose/vr 0. Duse-L By JoH/v H. 01.55A/ ma@ ma mee,

A rroRNEvs 3,163,6S6 ART iii? Film/HNS CUSHE PLASTC DEVKCES Robert Dusel, Brookfield, and .lohn lil.' Glsen, Mils r waultee, `Wis., assignors to )Pulp Reproduction Company, Y

Milwaukee, Wis., .a corporation of Wisconsin Filed Apr. 2, i962, Ser. No. 154,222 3 sllaims. tll. 25d-45) The present invention relates generally to improvements in the field of plastics, and relates more particu-V larly to the provision of an improved molded plastic article and the method of producing the same.

It is common practice to manufacture diverse articles such as, for example, portable picnic coolers, trays, boxes, buckets, various toys and the like of plastic materials. Many such articles are formed of a foamable material in granular or liquid form adapted to expand under the influence of heat.A When introduced in proper amounts into a mold and then expanded, an integral cellular body of the desired shape results which is light in weight and extremely economical in cost.

However, the molded articles thus produced are relatively fragile and areV susceptible to surface rupture and similar damage when bumped by or against hard objects.

Moreover, the cellular nature of the resultant body presents an unattractive and unfinished appearance which creates an impression of cheapness to prospective purchasers requiring further treatment to malte the samev more saleable. Also, while the relatively pervious or porous characteristic qualities areV advantageous for certain applications or usages, it is desirable in numerous instances to seal the exposed cells and impart-a relatively smooth finish to exposed surfaces.

Accordingly, it has been heretofore proposed to cover exposed surfaces of the expanded cellular bodies with a film or films of plastic thus forming a laminated `structure having an exposed outer surface or skin which 'is relatively dense, non-cellular and dent resistant. In some instances, the outer lm is obtained by using skin forming particles which adhere to the surface and form a relatively continuous cover as shown in U.S. Patent No. 2,950,505, dated August 30, 1960, to Jacob Frank, US. lJatent No. 2,954,589, dated October 4, i960, to Winthrop L. Brown, and U.S. Patent No. 2,948,651, dated August 9, 1960, to Harry O. Waag. However, in such methods itis necessary to initially cover the surfaceof the mold cavity witha coating or layer of the skin forming material, usually in powder, granular or liquid form, and then introduce the expandable material into the coated mold and thereafter heat the same to expand the material and thus form the final article, the coating operation being rather tedious and time-consuming.

In still other instances, the outer covering is obtained by using thermoplastic sheeting in forming the skin, the sheeting in some cases being drawn into complete conformity with the mold in an initial operation with the nomically producing laminated plastic articles of diverse shapes and sizes and having irregular surface contours andV an integral and relatively impervious vprotective skin which obviates the disadvantages heretofore attendant prior production methods and apparatus.

Another object of the present invention is to provide a practical production method and apparatus for the manufacture of composite plastic articles having cellular bodies and a dense protective skin tightly and integrally adhered thereto over its entire exposed surface, the improvements being exceptionally iiexible in their adaptations and use.

Still another object of the invention is to provide irnprovements in the art of producing molded plastic containers and similar articles having pre-designed surface irregularities for enhancing their appearance and formed with a continuous integral sciiti-resistant skin.

These and other objects and'advantages of the invention will become apparent from the following detailed description considered in conjunction with the accompanying drawing wherein; g

FIG. 1 is an exploded perspective view of a typical picnic cooler produced inV accordance with the invention, a portion ofthe inner liner being broken away to more clearly reveal the lip thereof; l

FiG. 2 is a fragmentary transverse vertical section through a typical pre-forming mold with a skin-forming sheet of thermoplastic film secured in position for lthe performance of the initial step of the improved method;

PEG. 3 is asimilar fragmentary section showingV the steplof partially pre-formlnU the thermoplastic sheet in thev mold with the aid of heat and suction;

FIG. 4 is a fragmentary transverse vertical section Y `illustrating the next step of the method wherein an entry FG. 5 is another transverse vertical section through a typical mold for linally forming the skin-covered article and showing the partially-pre-formed thermoplastic sheet inverted and positioned within the mold cavity with the expandable body-forming material being supplied thereto by way of the entrance hole in the sheet; and

FIG. 6 is a similar transverse vertical section showing the mold cavity filled and sealed with heat being supplied thereto to expand the body-forming material and the thermoplastic outer sheet into complete conformity withV the mold.

While the invention has been shown and described herein as being especially applicable to the production of containers such as picnic coolers withl partially pre-expanded polystyrene'beads being used for the body and polystyrene sheeting being used for the skin-forming outer covering, it should be understood'that numerous other articles may be advantageously produced by the improved method and other expandable materials and thermoplasinternally covered mold cavity then being filled with a f liquid foaming material as shown in US. Patent No. 2,753,642 dated .luly 10, 1956, to George C. Sullivan, and the sheeting in other cases merely being laid iiat across the open end of the mold and being expanded completely by full expansion of initially unexpanded beads when tic sheeting may be substituted in the method. It is also contemplated that certainV specific descriptive terminology used herein shall be giventhe broadest possible interpretation consistent with the disclosure. l

A typical picnic cooler produced in accordance with the improved method and by means of the improved apparatus is shown in FlG.L l. The picnic'cooler comprises, in general, a relatively deep body portion l0 having a separately formed inner liner 1l and provided with a cover l2. The box-like -body lt) is formed of a heatv expandable material `such as beaded polystyrene expanded into a cellular core which is covered by an impervious Vexternal skin formed by a thermoplastic sheet material as will be hereinafter more fully described. The body it! has an external embossed surface as illustrated at l to impart an attractive ornamental appearance, and the combined hinged handle and cover clamp 14, i4 is suitably secured to each end of the body llt) adjacent the upper open end thereof. The hner 1l is separately formed from a suitable impervious material and has an upper annular flange 1S which overlies the upper marginal edge or lip 16 of the body lil. The cover 12 is relatively shallow and may likewise be formed in accordance with the improved method hereinafter described. The cover may also be formed with embossed areas 17 over its outer surface, and recesses 13 are preferably provided in the cover adjacent the opposite ends thereof for reception of the adjacent clamp 14 carried by the boxlike body 10.

The improved and novel methodV is illustrated in FlGS. 2 to 6 inclusive and comprises generally the following steps. First, a at impervious thermoplastic sheet 2i) adapted to be stretched under the influence of heat and pressure and compatible with the expandable material from which the core is to be formed is selected. The iat thermoplastic sheet 29 is placed over the relatively smooth walled cavity 21 of a mold 22 with the edge portions of the sheet being secured about the mold by means of suitable clamps 23 as shown in FIG. 2. Next, the thermoplastic `sheet is subjected to heat as by means of a suitable electric heater Z4 and a vacuum is drawn within the mold cavity by means of a vacuum or suction pump 25 communicating with the cavity through a conduit 26 as shown in FIG. 3. By means of the sirnultaneous application of heat and vacuum, the sheet 2t? is thus pre-formed to the general outer contour of the body 10, the sheet assuming generally the shape of a receptacle having side and bottom walls 27, 28 respectively. With the aid of a suitable die 29 and circular knife 39, an aperture 31 is then formed in the bottom wall 2S to provide an entrance opening as will hereinafter more fully appear.

The thin vwalled receptacle thus formed from the thermoplastic sheet is then inverted and placed within the cavity of a mold formed by hollow side walls 33 hingedly secured as at 34 to a base 35, and the inner surfaces of the side walls 33 are provided with debossed or recessed areas 36 so that the mold has a contoured mold surface. The inner part 37 of the mold forming the male portion thereof is also hollow and is preferably formed with a plurality of perforations 38 in the wall thereof facing the mold cavity. The mold is furthermore provided with a cover 39 cooperating with the sides 33 to form the female half of the mold, the cover 39 likewise preferably being hollow and having a supply opening 40 therein corresponding and conforming to the aperture 31 formed in the bottom wall of the pre-formed thermoplastic receptacle so as to provide a passageway for introduction of a quantity of polystyrene beads 41 as shown in FIG. 5 wherein the polystyrene beads 41 are shown as being introduced into the mold with the aid of a funnel 42 or the like. After the cavity defined by the side and bottom walls 27, 28 of the pre-formed thermoplastic sheet and the perforated wall of the male half of the mold 37 has been substantially filled with heat expandable polystyrene beads, the entrance passage 40 in thecover 39 of the mold is covered by a closure 43 suitably clamped thereto. Heat is then conducted simultaneously to the hollow interiors 45 of the side walls 33 as by Way of conduits 46, and also to the hollow interior 47 of the male portion 37 of the mold as by way of conduits 4S as well as to the Vhollow interior 49 of the cover 33 as by way of the conduits 50. Upon such applicationof heat to the parts of the mold defining the mold cavity, the beaded polystyrene expands into a cellular mass as defined by the ,shape of the mold cavity and the expanding core forces the walls of the thermoplastic sheet into snug conformity with the debossed contoured mold surface and the polystyrene core also becomes firmly bonded to the inner surface of the polystyrene sheet to provide the core with an external protective skin, the surface of the final article being surface embossed.

The skin forming outer covering may be selected from any thermoplastic sheet material which 4is compatible with and will seal to the heat expandable material used in the method. The thermoplastic sheet material should be or" high density and may be of any desired thickness within a range which will permit the sheet to be drawn `into the mold to assume a given shape and be relatively self-supporting in order to serve its purpose in defining a space wit-hin which the heat expandable beads may be introduced as shown in FIG. 5. The heat expandable material is preferably in the nature of a thermoplastic resin such as partially expanded polystyrene beads, and these beads are supplied to the mold cavity formed between the walls 27, 28 of the thermoplastic sheet and the perforated outer wall of the male part of the mold. It has been found that pre-expanded polystyrene beads having a density in the range of about 2 to 6 lbs. per cubic foot are epsecially suitable and give good results, but the degree of pre-expansion may be varied to provide the desired density in the core. Pre-expansion of polystyrene beads is, of course, known in the art and is generally carried out by heating a layer lof the beads at approximately 260 F. for the time required to expand them to the desired density. The heat may be supplied t-o the hollow interiors of the mold in the form of steam, and the temperature employed is in the range of 260 to 280 F.

The articles thus produced may partake of various forms having desired embossed or raised surface characteristics, and the embossing may be complemented by the name of the producer or a prominent trademark. The final articles have a relatively porous cellular core which is protected intcriorly by the self-supporting liner and which is exteriorly covered by the integral skin forming thermoplastic sheet of high density which is, in fact, quite skuff resistant. The method is especially suitable for use in producing articles requiring deep draw, and picnic coolers and similar products produced in accordance with the method have achieved a high degree of commercial success. It should, of course, be understood that a wide variety of articles may be formed by the present method, and various available heat expandable materials may be used in forming the core as long as the matenials used for the core and for the skin are capable of being integrally united under the inuence of heat.

Various modes of carrying out the invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention.

We claim:

1. The method of producing an article of considerable depth and provided with irregular surface design contours in which the body is formed of a heat expandable material having a thermoplastic protective covering sheet laminated to any covering the embossed surface to thus provide an integral coposite structure, which method comprises, initially pre-forming a fiat impervious thermoplastic sheet by drawing it to the desired depth and general shape of the body by application of heat and vacuum, then forming an aperture in a wall of said initially preformed sheet to provide an entrance opening therein, placing the initially pre-formed sheet in a mold having an adjacent mold surface contoured to embody the irregularities to be imparted to the surface of the article, introducing a quantity of heat expandable material into the mold through the entrance opening formed in said initially pre-formed sheet, and finally subjecting the heat expandable material and the initially pre-formed sheet within the mold to heat to thereby expand said material and force said sheet into snug conformity with the oontoured mold surface to thus provide the final composite surface embossed and protectively covered article.

va flat impervious thermoplastic sheet by drawing it to the desired depth and general shape of the body by application of heat and vacuum to form a receptacle having Walls substantially devoid of surface irregularities, then Y orming an aperture in the bottom Wall of'said pre-formed side and bfottom Walls substantially Vdevoid ofV surface irregularities, then forming an aperture Yin the bottom Wall fof said pre-formed receptacle to provide an entrance opening therein, placing the pre-formed receptacle in a mold having an adjacent mold surface contoured to embody the irregularities to be imparted tothe surface ofthe iinal receptacle, introducing a quantity of heat expandable material into the mold through the entrance opening formed in the bottom wall of said pre-formed receptacle, and finally subjecting the heat expandable material and the 'pre-formed thermoplastic lreceptacle within the mold to heat tothereby expand said material and simultaneously lforce the walls of said receptacle into snug conformity With the contoured mold surface to thus provide the nal composite surface embossed and protectively covered receptacle.

3. The method of producing a receptacle of considerable cellular plastic having an impervious thermoplastic contours in which the body is formed of a heat expandable cellular plastic having an impervious thermoplastic protective lcovering sheet laminated to and covering the embossed surface to thus provide an integral composite structure, Whichkmethod comprises, initially pre-forming a at impervious thermoplastic sheet to the general contour of the body by applying heat and simultaneously vacuum drawing the same Iinto a smooth-surfaced mold to form a receptacle of the kdesired depth having side and bottom receptacle to provide an entranceopening therein, inverting the receptacle and placing'the same in a mold having :an adjacent mold surface contoured to embody the irregularities to be imparted to the surface of the receptacle, introducing a quantity 0f heat expandable polystyrene beads into the mold through the ventrance opening formed .in the bottom Wall of said pre-formed receptacle, and finally simultaneously subjecting both the ing :adherence of said beads to each other and to said thermoplastic sheet t0 thus provide the nal composite surface embossed and protectively covered receptacle.

References Cited in the file of this patent UNITED STATES PATENTS A2,753,642 VSullivan July 10, 1956 2,977,639 Barkhulf et al. Apr. 4, 1961 3,074,110 Mard et al. Jan. 22, 1963 v3,091,946 Kesling June 4, 1963 Kopitke May 12, 1942 

1. THE METHOD OF PRODUCING AN ARTICLE OF CONSIDERABLE DEPTH AND PROVIDED WITH IRREGULAR SURFACE DESIGN CONTOURS IN WHICH THE BODY IS FORMED OF A HEAT EXPANDABLE MATERIAL HAVING A THERMOPLASTIC PROTECTIVE COVERING SHEET LAMINATED TO ANY COVERING THE EMBOSSED SURFACE TO THUS PROVIDE AN INTEGRAL COPOSITE STRUCTURE, WHICH METHOD COMPRISES, INTIALLY PRE-FORMING A FLAT IMPERVIOUS THERMOPLASTIC SHEET BY DRAWING IT TO THE DESIRED DEPTH AND GENERAL SHAPE OF THE BODY BY APPLICATION OF HEAT AND VACUUM, THEN FORMING AN APERTURE IN A WALL OF SAID INTIALLY PREFORMED SHEET TO PROVIDE AN ENTRANCE OPENING THEREIN, PLACING THE INTIALLY PRE-FORMED SHEET IN A MOLD HAVING AN ADJACENT MOLD SURFACE CONTOURED TO EMBODY THE IRREGULARTIES TO BE IMPARTED TO THE SURFACE OF THE ARTICLE, INTRODUCING A QUANTITY OF HEAT EXPANDABLE MATERIAL INTO THE MOLD THROUGH THE ENTRANCE OPENING FORMED IN SAID INTIALLY PRE-FORMED SHEET, AND FINALLY SUBJECTING THE HEAT EXPANDABLE MATERIAL AND THE INTIALLY PRE-FORMED SHEET WITHIN THE MOLD TO HEAT TO THEREBY EXPAND SAID MATERIAL AND FORCE SAID SHEET INTO SNUG CONFORMITY WITH THE CONTOURED MOLD SURFACE TO THUS PROVIDE THE FINAL COMPOSITE SURFACE EMBOSSED AND PROTECTIVELY COVERED ARTICLE. 